Publications

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A parallel, adaptive overlay grid procedure is proposed for use in generating all-hex meshes for stochastic (SVE) and representative (RVE) volume elements in computational materials modeling. The mesh generation process is outlined including several new advancements such as data filtering to improve mesh quality from voxelated and 3D image sources, improvements to the primal contouring method for constructing material interfaces and pillowing to improve mesh quality at boundaries. We show specific examples in crystal plasticity and syntactic foam modeling that have benefitted from the proposed mesh generation procedure and illustrate results of the procedure with several practical mesh examples.

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Sculpt is a companion application to Cubit designed to run in parallel for generating all-hex meshes of complex geometry. It uses a unique overlay-grid procedure that extracts surfaces from a volume-fraction representation of the geometry. This allows for fast, automatic, fault-tolerant meshing in a high-performance computing (HPC) environment. Although Sculpt can be driven from Cubit as a GUI front-end, Sculpt was developed as a separate application so that it can be run independently from Cubit on HPC computing platforms. It was also designed as a separable software library so it can be easily integrated as an in-situ meshing solution within other codes. This work provides a brief technical discussion of the algorithms used in Sculpt as well as a complete user's manual. It includes details of the Cubit interface to Sculpt and the complete manual for the stand-alone application, including examples.

We describe new machine-learning-based methods to defeature CAD models for tetrahedral meshing. Using machine learning predictions of mesh quality for geometric features of a CAD model prior to meshing we can identify potential problem areas and improve meshing outcomes by presenting a prioritized list of suggested geometric operations to users. Our machine learning models are trained using a combination of geometric and topological features from the CAD model and local quality metrics for ground truth. We demonstrate a proof-of-concept implementation of the resulting work ow using Sandia's Cubit Geometry and Meshing Toolkit.

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Researchers review the challenges and opportunities that we are facing in the modeling and simulation of additive manufacturing processes for metals and the predictive representation of their mechanical performance at the different scales. They highlight the current modeling efforts taking place at the US Department of Energy National Nuclear Security Administration (NNSA) Laboratories, such as process modeling, microstructure modeling, properties modeling, performance and topology and process optimization. All these various modeling developments at different scales and regimes are necessary to move toward an integrated computational approach of process-structure-properties-performance that will ultimately enable the engineering and optimization of materials to specific performance requirements. Truchas, a continuum thermo-mechanical modeling tool originally designed for the simulation of casting processes, is being extended to simulate directed energy deposition additive manufacturing processes.

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We provide a template-based approach for generating locally refined all-hex meshes. We focus specifically on refinement of initially structured grids utilizing a 2-refinement approach where uniformly refined hexes are subdivided into eight child elements. The refinement algorithm consists of identifying marked nodes that are used as the basis for a set of four simple refinement templates. The target application for 2-refinement is a parallel grid-based all-hex meshing tool for high performance computing in a distributed environment. The result is a parallel consistent locally refined mesh requiring minimal communication and where minimum mesh quality is greater than scaled Jacobian 0.3 prior to smoothing.

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A parallel, adaptive overlay grid procedure is proposed for use in generating all-hex meshes for stochastic (SVE) and representative (RVE) volume elements in computational materials modeling. The mesh generation process is outlined including several new advancements such as data filtering to improve mesh quality from voxelated and 3D image sources, improvements to the primal contouring method for constructing material interfaces and pillowing to improve mesh quality at boundaries. We show specific examples in crystal plasticity and syntactic foam modeling that have benefitted from the proposed mesh generation procedure and illustrate results of the procedure with several practical mesh examples.

We propose a new post-processing procedure for automatically adjusting node locations of an all-hex mesh to better match the volume of a reference geometry. Hexahedral meshes generated via an overlay grid procedure, where a precise reference geometry representation is unknown or is impractical to use, do not provide for precise volumetric preservation. A discrete volume fraction representation of the reference geometry MI on an overlay grid is compared with a volume fraction representation of a 3D finite element mesh MO. This work proposes a procedure that uses the localized discrepancy between MI and MO to drive node relocation operations to more accurately match a reference geometry. We demonstrate this procedure on a wide range of hexahedral meshes generated with the Sculpt code and show improved volumetric preservation while still maintaining acceptable mesh quality.

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Welcome to CUBIT, the Sandia National Laboratory automated mesh generation toolkit. CUBIT is a full-featured software toolkit for robust generation of two- and three-dimensional finite element meshes (grids) and geometry preparation. Its main goal is to reduce the time to generate meshes, particularly large hex meshes of complicated, interlocking assemblies. It is a solidmodeler based preprocessor that meshes volumes and surfaces for finite element analysis.

The mechanical properties of materials systems are highly influenced by various features at the microstructural level. The ability to capture these heterogeneities and incorporate them into continuum-scale frameworks of the deformation behavior is considered a key step in the development of complex non-local models of failure. In this study, we present a modeling framework that incorporates physically-based realizations of polycrystalline aggregates from a phase field (PF) model into a crystal plasticity finite element (CP-FE) framework. Simulated annealing via the PF model yields ensembles of materials microstructures with various grain sizes and shapes. With the aid of a novel FE meshing technique, FE discretizations of these microstructures are generated, where several key features, such as conformity to interfaces, and triple junction angles, are preserved. The discretizations are then used in the CP-FE framework to simulate the mechanical response of polycrystalline α-iron. It is shown that the conformal discretization across interfaces reduces artificial stress localization commonly observed in non-conformal FE discretizations. The work presented herein is a first step towards incorporating physically-based microstructures in lieu of the overly simplified representations that are commonly used. In broader terms, the proposed framework provides future avenues to explore bridging models of materials processes, e.g. additive manufacturing and microstructure evolution of multi-phase multi-component systems, into continuum-scale frameworks of the mechanical properties.

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CUBIT is a full-featured software toolkit for robust generation of two- and three-dimensional finite element meshes (grids) and geometry preparation. Its main goal is to reduce the time to generate meshes, particularly large hex meshes of complicated, interlocking assemblies. It is a solid-modeler based preprocessor that meshes volumes and surfaces for finite element analysis. Mesh generation algorithms include quadrilateral and triangular paving, 2D and 3D mapping, hex sweeping and multi-sweeping, tetrahedral meshing, and various special purpose primitives. CUBIT contains many algorithms for controlling and automating much of the meshing process, such as automatic scheme selection, interval matching, sweep grouping, and also includes state-of-the-art smoothing algorithms.

This paper presents an end-to-end design process for compliance minimization based topological optimization of cellular structures through to the realization of a final printed product. Homogenization is used to derive properties representative of these structures through direct numerical simulation of unit cell models of the underlying periodic structure. The resulting homogenized properties are then used assuming uniform distribution of the cellular structure to compute the final macro-scale structure. A new method is then presented for generating an STL representation of the final optimized part that is suitable for printing on typical industrial machines. Quite fine cellular structures are shown to be possible using this method as compared to other approaches that use nurb based CAD representations of the geometry. Finally, results are presented that illustrate the fine-scale stresses developed in the final macro-scale optimized part and suggestions are made as to incorporate these features into the overall optimization process.

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This paper explores potential methods for characterizing the meshing complexity of solid geometry. While numerous metrics exist to measure the quality of the finite element, there are currently no metrics that measure the quality of a solid with respect to its meshing complexity. The meshing complexity of a solid is defined by how difficult it is to generate a valid finite element mesh for a given solid. There are many variables that affect meshing complexity. This paper seeks to discuss methods that are decoupled from more subjective variables such as user expertise and software maturity, and it will focus on methods that describe the topological and geometric aspects of a solid. It will present techniques based on: medial axis transformation, wavelets, curvature, proximity, intersection, heuristic topology search, and the measurement of space (volume/area/length) and will analyze their suitability as meshing complexity metrics.

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In order to better incorporate microstructures in continuum scale models, we use a novel finite element (FE) meshing technique to generate three-dimensional polycrystalline aggregates from a phase field grain growth model of grain microstructures. The proposed meshing technique creates hexahedral FE meshes that capture smooth interfaces between adjacent grains. Three dimensional realizations of grain microstructures from the phase field model are used in crystal plasticity-finite element (CP-FE) simulations of polycrystalline a -iron. We show that the interface conformal meshes significantly reduce artificial stress localizations in voxelated meshes that exhibit the so-called "wedding cake" interfaces. This framework provides a direct link between two mesoscale models - phase field and crystal plasticity - and for the first time allows mechanics simulations of polycrystalline materials using three-dimensional hexahedral finite element meshes with realistic topological features.

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In this work we provide a template-based approach for generating locally refined all-hex meshes. We focus specifically on refinement of initially structured grids utilizing a 2-refinement approach where uniformly refined hexes are subdivided into eight child elements. The refinement algorithm consists of identifying marked nodes that are used as the basis for a set of four simple refinement templates. The target application for 2-refinement is a parallel grid-based all-hex meshing tool for high performance computing in a distributed environment. The result is a parallel consistent locally refined mesh requiring minimal communication and where minimum mesh quality is greater than scaled Jacobian 0.4 prior to smoothing.

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We propose a method to automatically defeature a CAD model by detecting irrelevant features using a geometry-based size field and a method to remove the irrelevant features via facet-based operations on a discrete representation. A discrete B-Rep model is first created by obtaining a faceted representation of the CAD entities. The candidate facet entities are then marked for reduction using a geometry-based size field. This is accomplished by estimating local mesh sizes based on geometric criteria. If the field value at a facet entity goes below a user-specified threshold value then it is identified as an irrelevant feature and is marked for reduction. The reduction of marked facet entities is performed using various facet operators. Care is taken to retain a valid geometry and topology of the discrete model throughout the procedure. The original model is not altered as the defeaturing is performed on a separate discrete model. Associativity between the entities of the discrete model and that of original CAD model is maintained in order to decode the attributes and boundary conditions applied on the original CAD entities onto the mesh via the entities of the discrete model. Example models are presented to illustrate the effectiveness of the proposed approach. © Springer-Verlag London Limited 2012.

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Computational simulation must often be performed on domains where materials are represented as scalar quantities or volume fractions at cell centers of an octree-based grid. Common examples include bio-medical, geotechnical or shock physics calculations where interface boundaries are represented only as discrete statistical approximations. In this work, we introduce new methods for generating Lagrangian computational meshes from Eulerian-based data. We focus specifically on shock physics problems that are relevant to ASC codes such as CTH and Alegra. New procedures for generating all-hexahedral finite element meshes from volume fraction data are introduced. A new primal-contouring approach is introduced for defining a geometric domain. New methods for refinement, node smoothing, resolving non-manifold conditions and defining geometry are also introduced as well as an extension of the algorithm to handle tetrahedral meshes. We also describe new scalable MPI-based implementations of these procedures. We describe a new software module, Sculptor, which has been developed for use as an embedded component of CTH. We also describe its interface and its use within the mesh generation code, CUBIT. Several examples are shown to illustrate the capabilities of Sculptor.

Most adaptive mesh generation algorithms employ a 3-refinement method. This method, although easy to employ, provides a mesh that is often too coarse in some areas and over refined in other areas. Because this method generates 27 new hexes in place of a single hex, there is little control on mesh density. This paper presents an adaptive all-hexahedral grid-based meshing algorithm that employs a 2-refinement method. 2-refinement is based on dividing the hex to be refined into eight new hexes. This method allows a greater control on mesh density when compared to a 3-refinement procedure. This adaptive all-hexahedral meshing algorithm provides a mesh that is efficient for analysis by providing a high element density in specific locations and a reduced mesh density in other areas. In addition, this tool can be effectively used for inside-out hexahedral grid based schemes, using Cartesian structured grids for the base mesh, which have shown great promise in accommodating automatic all-hexahedral algorithms. This adaptive all-hexahedral grid-based meshing algorithm employs a 2-refinement insertion method. This allows greater control on mesh density when compared to 3-refinement methods. This algorithm uses a two layer transition zone to increase element quality and keeps transitions from lower to higher mesh densities smooth. Templates were introduced to allow both convex and concave refinement.

The ability to automatically morph an existing mesh to conform to geometry modifications is a necessary capability to enable rapid prototyping of design variations. This paper compares six methods for morphing hexahedral and tetrahedral meshes, including the previously published FEMWARP and LBWARP methods as well as four new methods. Element quality and performance results show that different methods are superior on different models. We recommend that designers of applications that use mesh morphing consider both the FEMWARP and a linear simplex based method.

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The generation of all-hexahedral finite element meshes has been an area of ongoing research for the past two decades and remains an open problem. Unconstrained plastering is a new method for generating all-hexahedral finite element meshes on arbitrary volumetric geometries. Starting from an unmeshed volume boundary, unconstrained plastering generates the interior mesh topology without the constraints of a pre-defined boundary mesh. Using advancing fronts, unconstrained plastering forms partially defined hexahedral dual sheets by decomposing the geometry into simple shapes, each of which can be meshed with simple meshing primitives. By breaking from the tradition of previous advancing-front algorithms, which start from pre-meshed boundary surfaces, unconstrained plastering demonstrates that for the tested geometries, high quality, boundary aligned, orientation insensitive, all-hexahedral meshes can be generated automatically without pre-meshing the boundary. Examples are given for meshes from both solid mechanics and geotechnical applications.

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Grid-based mesh generation methods have been available for many years and can provide a reliable method for meshing arbitrary geometries with hexahedral elements. The principal use for these methods has mostly been limited to biological-type models where topology that may incorporate sharp edges and curve definitions are not critical. While these applications have been effective, robust generation of hexahedral meshes on mechanical models, where the topology is typically of prime importance, impose difficulties that existing grid-based methods have not yet effectively addressed. This work introduces a set of procedures that can be used in resolving the features of a geometric model for grid-based hexahedral mesh generation for mechanical or topology-rich models.

We propose a method to automatically defeature a CAD model by detecting irrelevant features using a geometry-based size field and a method to remove the irrelevant features via facet-based operations on a discrete representation. A discrete B-Rep model is first created by obtaining a faceted representation of the CAD entities. The candidate facet entities are then marked for reduction by using a geometry-based size field. This is accomplished by estimating local mesh sizes based on geometric criteria. If the field value at a facet entity goes below a user specified threshold value then it is identified as an irrelevant feature and is marked for reduction. The reduction of marked facet entities is primarily performed using an edge collapse operator. Care is taken to retain a valid geometry and topology of the discrete model throughout the procedure. The original model is not altered as the defeaturing is performed on a separate discrete model. Associativity between the entities of the discrete model and that of original CAD model is maintained in order to decode the attributes and boundary conditions applied on the original CAD entities onto the mesh via the entities of the discrete model. Example models are presented to illustrate the effectiveness of the proposed approach.

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Unconstrained Plastering is a new algorithm with the goal of generating a conformal all-hexahedral mesh on any solid geometry assembly. Paving[1] has proven reliable for quadrilateral meshing on arbitrary surfaces. However, the 3D corollary, Plastering [2][3][4][5], is unable to resolve the unmeshed center voids due to being over-constrained by a pre-existing boundary mesh. Unconstrained Plastering attempts to leverage the benefits of Paving and Plastering, without the over-constrained nature of Plastering. Unconstrained Plastering uses advancing fronts to inwardly project unconstrained hexahedral layers from an unmeshed boundary. Only when three layers cross, is a hex element formed. Resolving the final voids is easier since closely spaced, randomly oriented quadrilaterals do not over-constrain the problem. Implementation has begun on Unconstrained Plastering, however, proof of its reliability is still forthcoming. © 2005 Springer-Verlag Berlin Heidelberg.

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This paper presents an automated tool for local, conformal refinement of all-hexahedral meshes based on the insertion of multi-directional twist planes into the spatial twist continuum. The refinement process is divided into independent refinement steps. In each step, an inserted twist plane modifies a single sheet or two parallel hex sheets. Six basic templates, chosen and oriented based on the number of nodes selected for refinement, replace original mesh elements. The contributions of this work are (1) the localized refinement of mesh regions defined by individual or groups of nodes, element edges, element faces or whole elements within an all-hexahedral mesh, (2) the simplification of template-based refinement into a general method and (3) the use of hex sheets for the management of template insertion in multi-directional refinement.

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This paper proposes a method for predicting the complexity of meshing computer aided design (CAD) geometries with unstructured, hexahedral, finite elements. Meshing complexity refers to the relative level of effort required to generate a valid finite element mesh on a given CAD geometry. A function is proposed to approximate the meshing complexity for single part CAD models. The function is dependent on a user defined element size as well as on data extracted from the geometry and topology of the CAD part. Several geometry and topology measures are proposed, which both characterize the shape of the CAD part and detect configurations that complicate mesh generation. Based on a test suite of CAD models, the function is demonstrated to be accurate within a certain range of error. The solution proposed here is intended to provide managers and users of meshing software a method of predicting the difficulty in meshing a CAD model. This will enable them to make decisions about model simplification and analysis approaches prior to mesh generation.

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New algorithms are proposed for the modification of a mixed hexahedra-tetrahedra element mesh to maintain compatibility by the insertion of pyramid elements. Several methods for generation of the pyramids are presented involving local tetrahedral transformations and/or node insertion near the hex/tet interface. Local smoothing and topological operations improve the quality of the transition region. Results show superior performance of the resulting elements in a commercial finite-element code over non-conforming interface conditions. © 2001 Elsevier Science B.V. All rights reserved.

A method for decomposing a volume with a prescribed quadrilateral surface mesh, into a hexahedral-dominated mesh is proposed. With this method, known as Hex-Morphing (H-Morph), an initial tetrahedral mesh is provided. Tetrahedra are transformed and combined starting from the boundary and working towards the interior of the volume. The quadrilateral faces of the hexahedra are treated as internal surfaces, which can be recovered using constrained triangulation techniques. Implementation details of the edge and face recovery process are included. Examples and performance of the H-Morph algorithm are also presented.

H-Morph is a new automatic algorithm for the generation of a hexahedral-dominant finite element mesh for arbitrary volumes. The H-Morph method starts with an initial tetrahedral mesh and systematically transforms and combines tetrahedra into hexahedra. It uses an advancing front technique where the initial front consists of a set of prescribed quadrilateral surface facets. Fronts arc individually processed by recovering each of the six quadrilateral faces of a hexahedron from the tetrahedral mesh. Recovery techniques similar to those used in boundary constrained Delaunay mesh generation are used. Tetrahedra internal to the six hexahedral faces are then removed and a hexahedron is formed. At any time during the H-Morph procedure a valid mixed hexahedral-tetrahedral mesh is in existence within the volume. The procedure continues until no tetrahedra remain within the volume, or tetrahedra remain which cannot be transformed or combined into valid hexahedral elements. Any remaining tetrahedra are typically towards the interior of the volume, generally a less critical region for analysis. Transition from tetrahedra to hexahedra in the final mesh is accomplished through pyramid-shaped elements. Advantages of the proposed method include its ability to conform to an existing quadrilateral surface mesh, its ability to mesh without the need to decompose or recognize special classes of geometry, and its characteristic well-aligned layers of elements parallel to the boundary. Example test cases are presented on a variety of models. Copyright © 2000 John Wiley & Sons, Ltd.

A co-simulation tool based on finite element principles has been developed to solve coupled electrostatic-structural problems. An automated mesh morphing algorithm has been employed to update the field mesh after structural deformation. The co-simulation tool has been successfully applied to the hysteric behavior of a MEMS switch.

The CUBIT mesh generation environment is a two- and three-dimensional finite element mesh generation tool which is being developed to pursue the goal of robust and unattended mesh generation--effectively automating the generation of quadrilateral and hexahedral elements. It is a solid-modeler based preprocessor that meshes volume and surface solid models for finite element analysis. A combination of techniques including paving, mapping, sweeping, and various other algorithms being developed are available for discretizing the geometry into a finite element mesh. CUBIT also features boundary layer meshing specifically designed for fluid flow problems. Boundary conditions can be applied to the mesh through the geometry and appropriate files for analysis generated. CUBIT is specifically designed to reduce the time required to create all-quadrilateral and all-hexahedral meshes. This manual is designed to serve as a reference and guide to creating finite element models in the CUBIT environment.